A cross-laminated air-gap transformer core
By setting segmented air gaps and magnetic circuit air gap effects in the core of the cross-laminated open-gap transformer, the shortcomings of existing cores in terms of noise and anti-saturation performance are solved, achieving the effects of low noise, low leakage flux and low loss.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- DONGGUAN LEADER ELECTRONICS
- Filing Date
- 2025-10-14
- Publication Date
- 2026-08-04
AI Technical Summary
Existing cross-structure and stacked structure transformer cores are insufficient in terms of noise reduction and anti-saturation performance, making it difficult to meet the needs of power electronic equipment with high noise control requirements.
It adopts a cross-stacked structure of four types of strip silicon steel sheets with segmented air gaps in the middle, and uses high-temperature resistant insulating materials to form a magnetic circuit air gap effect, adjust the magnetic permeability of the magnetic circuit, and reduce magnetic leakage and noise.
It achieves core performance with low noise, low leakage flux and low loss, improves anti-saturation performance and reduces surge current.
Smart Images
Figure CN224595355U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of transformer technology, and in particular to a cross-laminated open-gap transformer core. Background Technology
[0002] In the field of customized power electronics transformers, such as UPS, PCS, and EPS transformers, the cores are typically rectangular. The manufacturing processes for rectangular cores are mainly classified into cross-structure and stacked structure. Cross-structure cores are composed of three types of strips (A, B, and C), and feature low no-load current, low noise, low leakage flux, and low additional core losses. Stacked structure cores, on the other hand, are composed of two types of strips (A and B). They have a high no-load current. Two air gaps can be added between the upper and lower yokes and the core columns to increase the no-load current, lowering the magnetic permeability of the core and improving its anti-saturation capability, thereby reducing the starting surge current. However, this also increases the leakage flux, leading to higher additional core losses and noise.
[0003] Power supply equipment such as UPS, PCS, and EPS uses semiconductor components to complete the AC-DC-AC process. The front end is rectified and isolated by a transformer, while the back end is inverted and stepped up and isolated by another transformer. This results in the transformer carrying a large amount of harmonic voltage and current, thus increasing its noise. These power supply devices are often used in office environments with high noise control requirements, and the transformer is a major source of noise; therefore, the noise control requirements for these transformers are higher than for ordinary transformers. Furthermore, the power grid and the entire system inevitably include switching control devices. If the inrush current is too large, the switch will often trip. For these reasons, using a cross-core transformer results in lower noise, but due to its low magnetic reluctance, the core is prone to saturation, leading to a larger inrush current. Using a stacked core transformer, the magnetic reluctance can be increased by adding air gaps in the magnetic circuit, improving the core's anti-saturation performance and reducing inrush current. However, with the air gaps completely exposed to air at both ends, the noise will be higher, and losses will also increase due to increased leakage flux.
[0004] Therefore, in scenarios where transformer noise reduction is critical, the existing cross-structure or stacked core transformers have significant shortcomings and urgently need improvement. Utility Model Content
[0005] This utility model discloses a cross-laminated open-air-gap transformer core, specifically relating to a novel transformer core structure. The core is composed of four types of laminations, with segmented air gaps set in the middle of the core column. This not only reduces transformer noise but also reduces transformer losses, thus combining the advantages of interleaved and stacked transformer cores and solving the problems mentioned in the background art.
[0006] The technical solution of this utility model is as follows: a cross-laminated open-air gap transformer core, comprising four types of strip silicon steel sheets: A-sheet, B-sheet, C-sheet and D-sheet, which are composed of multiple layers of strip silicon steel sheets cross-stacked together. Each layer forms two opposing mountain-shaped sheets, and a segmented air gap is provided between the adjacent core columns of the two mountain-shaped sheets.
[0007] Furthermore, the cross-laminated open-gap transformer core is composed of one A lamination, three B laminations, one C lamination, and three D laminations stacked in a cross-laminated manner in each layer.
[0008] Furthermore, the cross-laminated open-gap transformer core is assembled into two mountain-shaped sections, each layer, using strip silicon steel sheets. The upper half of the first layer is assembled into mountain-shaped section one, where D strips are placed vertically first, followed by A strips stacked horizontally above the D strips, and then B strips stacked on the left and right ends of the A strips. The lower half of the first layer is assembled into mountain-shaped section two, where two D strips are placed vertically on the left and right sections first, followed by C strips stacked horizontally below the D strips, and then B strips stacked vertically in the middle of the C strips. The upper half of the second layer is assembled into mountain-shaped section two, and the lower half is assembled into mountain-shaped section one. The third and fourth layers are then assembled in a similar cyclical manner until the assembly of the cross-laminated open-gap transformer core is completed.
[0009] As a preferred embodiment, the segmented air gap is located at the position where the iron core column is divided into two parts in the middle, and the first and second mountain-shaped plates are symmetrical in shape.
[0010] Furthermore, a high-temperature resistant insulating material is provided at the contact surface of the combined mountain-shaped sheet one and mountain-shaped sheet two to form a magnetic circuit air gap effect.
[0011] Preferably, the high-temperature resistant insulating material is FR-4 epoxy resin insulating board.
[0012] Furthermore, the air gap in the magnetic circuit of the iron core can be flexibly adjusted by adjusting the thickness of the high-temperature resistant insulating material.
[0013] Furthermore, the strips are stacked and assembled in a cross pattern, with through holes at the intersections. After stacking, the corresponding through holes pass through the fixing posts for fixation.
[0014] This utility model of a cross-laminated open-air-gap core transformer, based on practical considerations, places the air gap in the middle of the core column, and compared with the prior art, has the following advantages: 1. It adopts a cross-laminated structure, resulting in low noise and low magnetic leakage; 2. An air gap is opened in the middle of the core column, which can adjust the magnetic permeability of the magnetic circuit, improve the anti-saturation performance of the iron core, and reduce the surge current. 3. An air gap is opened in the middle of the core column and it is wrapped by the coil, which can reduce the additional losses caused by leakage flux. Attached Figure Description
[0015] Figure 1 This is a schematic diagram of a cross-structure rectangular iron core. Figure 2 This is a schematic diagram of a stacked rectangular iron core structure; Figure 3 This is a schematic diagram of the cross-laminated open-gap iron core structure of this utility model; Figure 4 This is a schematic diagram of the assembly and stacking structure of the iron core of this utility model; Figure 5 The circuit diagram for the transformer of this utility model is shown.
[0016] The markings in the attached diagram are: 1. Strip A; 2. Strip B; 3. Strip C; 4. Strip D; 5. Segmented air gap; 6. Through hole; 7. Mountain-shaped strip one; 8. Mountain-shaped strip two. Detailed Implementation
[0017] The present invention will be further described below with reference to the accompanying drawings and embodiments, but these descriptions are not intended to limit the scope of the present invention.
[0018] In existing technologies, the rectangular core structure of custom power electronic transformers includes cross-structure and stacked structure. Cross-structure cores, such as... Figure 1 As shown, it is composed of three types of strips, A, B, and C, and features low no-load current, low noise, low leakage flux, and low additional core loss. The stacked core structure, as shown... Figure 2 As shown, it is composed of two types of strips, A and B. The core has a large no-load current. Two air gaps can be added between the upper and lower yokes and the core column to increase the no-load current, reduce the magnetic permeability of the core magnetic circuit, improve the core's anti-saturation ability, and thus reduce the starting surge current. However, at the same time, it will also increase the core's leakage flux, thus increasing the core's additional losses and noise.
[0019] In scenarios where high noise reduction is required for transformers, the existing cross-laminated or stacked core transformers have significant shortcomings. This invention provides a cross-laminated open-gap transformer core that combines the advantages of both interleaved and stacked core transformers, effectively avoiding their shortcomings.
[0020] like Figure 3 As shown, the cross-laminated open-air gap transformer core of this utility model includes four types of strip silicon steel sheets: A strip 1, B strip 2, C strip 3 and D strip 4. It is composed of multiple layers of strip silicon steel sheets cross-stacked together. Each layer forms two opposing mountain-shaped sheets. A segmented air gap 5 is provided between the adjacent core columns of the two mountain-shaped sheets.
[0021] The core of a cross-laminated open-gap transformer consists of one A-strip 1, three B-strips 2, one C-strip 3, and three D-strips 4, which are cross-laminated together.
[0022] like Figure 4 The diagram shows the assembly and stacking structure of the core layers of this utility model, where (a) is a schematic diagram of the first layer structure and (b) is a schematic diagram of the second layer structure. The cross-laminated open-gap transformer core is constructed by assembling strip silicon steel sheets into mountain-shaped sheet 7 and mountain-shaped sheet 8 in each layer. The upper half of the first layer is assembled into mountain-shaped sheet 7. First, strip D 4 is placed vertically, then strip A 1 is stacked horizontally above strip D 4, and then strip B 2 is stacked at the left and right ends of strip A 1. The lower half of the first layer is assembled into mountain-shaped sheet 8. First, two strip D 4s are placed vertically on the left and right sections, then strip C 3 is stacked horizontally below strip D 4, and then strip B 1 is stacked vertically in the middle of strip C 3. The upper half of the second layer is assembled into mountain-shaped sheet 8, and the lower half is assembled into mountain-shaped sheet 7. The third and fourth layers are then constructed in a cyclical manner until the assembly of the cross-laminated open-gap transformer core is completed. The strips are stacked and assembled in a cross pattern, with through holes 6 at the intersections. After stacking, the corresponding through holes 6 are passed through and fixed to the fixing posts.
[0023] In this embodiment, the segmented air gap 5 is set at the position where the iron core column is divided into two, and the first mountain-shaped piece 7 and the second mountain-shaped piece 8 are symmetrical in shape.
[0024] High-temperature resistant insulating material is provided at the contact surface of the combined mountain-shaped plate 7 and mountain-shaped plate 8 to form a magnetic circuit air gap effect. In this embodiment, the high-temperature resistant insulating material used is FR-4 epoxy resin insulating board. The air gap of the iron core magnetic circuit can be flexibly adjusted by adjusting the thickness of the high-temperature resistant insulating material.
[0025] In the field of customized power electronics transformers, such as power supply equipment like UPS, PCS, and EPS, the circuit principle utilizes semiconductor components to realize the AC-DC-AC process, such as... Figure 5 As shown, the front end is rectified after isolation by a transformer, and the back end is stepped up and isolated by a transformer after inversion. This results in the transformer being loaded with a large amount of harmonic voltage and current, thus increasing the transformer's noise. UPS uninterruptible voltage systems are often used in office environments with high noise reduction requirements, and the transformer is a major source of noise; therefore, the noise requirements for these types of transformers are higher than for ordinary transformers. Furthermore, the power grid and the entire system inevitably include switching control devices; if the inrush current is too large, the switch will often trip. For these reasons, if using… Figure 1 The cross-core structure shown has lower transformer noise, but lower magnetic reluctance makes the core prone to saturation, leading to larger inrush currents. However, if a cross-core structure is used... Figure 2 The stacked core structure shown can increase magnetic reluctance by adding air gaps in the magnetic circuit, thereby improving the core's anti-saturation performance and reducing surge current. However, since the air gaps are set at both ends and completely exposed to air, the noise will be relatively high, and the loss will also increase due to increased leakage flux. Using... Figure 3 The cross-laminated open-gap iron core of this utility model can achieve low noise and low magnetic leakage. The open-gap in the middle of the core column can adjust the magnetic permeability of the magnetic circuit, improve the anti-saturation performance of the iron core, and reduce the surge current. At the same time, the open-gap in the middle of the core column is wrapped by the coil, which can reduce the additional loss caused by magnetic leakage.
[0026] The above description is merely a preferred embodiment of the present utility model and is not intended to limit the present utility model in any form or substance. All technical solutions within the scope of the present utility model's concept are protected by the present utility model. Any equivalent changes and modifications made to the above embodiments based on the substantive technology of the present utility model should also be considered within the scope of protection of the present utility model.
Claims
1. A cross-laminated gas- gap core for a transformer, characterized by: It includes four types of strip silicon steel sheets: A strip, B strip, C strip and D strip. It is composed of multiple layers of strip silicon steel sheets stacked in a cross-stacked manner. Each layer forms two opposing mountain-shaped sheets, and a segmented air gap is provided between the adjacent iron core columns of the two mountain-shaped sheets.
2. The cross-laminated open-creepage air-gap transformer core of claim 1, wherein: The cross-laminated open-gap transformer core is composed of one A lamination, three B laminations, one C lamination, and three D laminations stacked in a cross-laminated manner in each layer.
3. The cross-laminated open-creek transformer core of claim 2, wherein: The cross-laminated open-gap transformer core is assembled into two mountain-shaped sections, one for each layer, using strip silicon steel sheets. The upper half of the first layer is assembled into mountain-shaped section one, where D-shaped sheets are placed vertically first, followed by A-shaped sheets stacked horizontally above the D-shaped sheets, and then B-shaped sheets stacked on the left and right ends of the A-shaped sheets. The lower half of the first layer is assembled into mountain-shaped section two, where two D-shaped sheets are placed vertically on the left and right sides first, followed by C-shaped sheets stacked horizontally below the D-shaped sheets, and then B-shaped sheets stacked vertically in the middle of the C-shaped sheets. The upper half of the second layer is assembled into mountain-shaped section two, and the lower half is assembled into mountain-shaped section one. The third and fourth layers are assembled in a similar cyclical manner until the cross-laminated open-gap transformer core is completed.
4. The cross-laminated open-creek transformer core of claim 3, wherein: The segmented air gap is located at the position where the iron core column is divided into two parts in the middle, and the first and second mountain-shaped plates are symmetrical in shape.
5. The cross-laminated open-creek transformer core of claim 1, wherein: A high-temperature resistant insulating material is placed at the contact surface of the two mountain-shaped plates to form a magnetic circuit air gap effect.
6. The cross-laminated open-creek transformer core of claim 5, wherein: The high-temperature resistant insulating material is FR-4 epoxy resin insulating board.
7. The cross-laminated open-creek transformer core of claim 5, wherein: The thickness of the high-temperature resistant insulating material is adjustable, which is used to adjust the air gap of the iron core magnetic circuit.
8. The cross-laminated open-creek transformer core of claim 1, wherein: The strips are stacked and assembled in a cross pattern, with through holes at the intersections. After stacking, the corresponding through holes are passed through and fixed to the posts.